Reinforced packaging system

ABSTRACT

A reinforced packaging system is provided that includes a slit and an insert at a location in the foam frame that is susceptible to puncture. The presence of the slit and insert provides localized support against puncture by the shipped unit or an external component of the shipped unit. The insert may be composed of a paper, plastic, or other suitable product that is able to absorb the force from the shipped unit and transfer this force across the insert and the adjacent foam.

TECHNICAL FIELD

The present disclosure relates generally to the field of packaging, and,more particularly, to a reinforced packaging technique for the shipmentof computer systems and other products.

BACKGROUND

Computer systems, as well as other products, are shipped worldwide tocustomers. These products must be packaged in a manner that insures thatthe products reach their destination without being damaged during theshipping process. Typically, the unit is enclosed for shipment within aprotective foam frame. Once the unit is placed within the protectivefoam frame, the foam frame is slid into a cardboard box for shipment.The foam frame cushions the unit against the customary movement andjostling that is typical in the shipping process.

In the computer industry, the physical size of many computer systems isdecreasing. In particular, many server systems are becoming thinner.Despite this decrease in physical size, the feature set of many computersystems continues to grow in complexity. As an example, a server systemmay have a size of 1U (1 3/4″ of thickness) and include within the casedual processors, multiple hard drives, and a backup power system. Theplacement of these features within a single server system leads to anincrease in component density within the server unit. In addition, someserver systems included parts that protrude externally from the chassisof the server system. As an example, some server systems may include anexternal power dongle or mounting flanges that are external to thechassis of the computer system. If a unit that includes an externalcomponent is dropped, depending on the angle of the drop and the shapeof the external component, the external component may cut through theprotective foam frame. If this occurs, the external component mayencounter a hard stop once the external component reaches a hardsurface, damaging the external component or the entire unit. Thepossibility of the unit cutting through the foam is exacerbated when theunit itself is heavy, as in the case of some server units. In the caseof server units, protecting the server unit from damage is critical, asthe server unit is often a vital piece of a computer network, ascompared with a desktop or client computer.

SUMMARY

In accordance with the present disclosure, a packaging system isprovided that includes a foam frame. Within the foam frame, at alocation that is susceptible to puncture, is a slit and an insert withinthe slit. The insert may be composed of a paper or plastic material. Theinsert cushions the shipped unit against a hard stop by prevent theshipped unit from puncturing through the foam frame. When the shippedunit contacts the insert, the insert transfers the force of the shippedunit across the surface area of the insert, which in turn transfers thisforce across the adjacent foam, preventing the unit from puncturingthrough the foam.

A technical advantage of the present disclosure is the structure of thedisclosed packaging system provides a solution that can be localized tothe weakest points of the foam frame. As such, it is not necessary tohave an insert throughout the entire foam frame. Instead, the insert isplaced in only those location that are know, whether through testing orotherwise, to be the most susceptible to puncture by the shipped unit.Another technical advantage of the present invention is a packagingsystem that prevents damage to the shipped unit without increasing thecost or shipping weight of the package. Because the insert is placed inthe area or areas that are the most susceptible to puncture, the costand weight of the packaging system is not significantly increased. Othertechnical advantages will be apparent to those of ordinary skill in theart in view of the following specification, claims, and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present embodiments and advantagesthereof may be acquired by referring to the following description takenin conjunction with the accompanying drawings, in which like referencenumbers indicate like features, and wherein:

FIG. 1 is a pictorial view of a foam frame;

FIG. 2 is a pictorial view of a corner support of the foam frame of FIG.1; and

FIG. 3 is a cross-sectional view of the corner support of FIG. 2, takenalong the line 3-3 of FIG. 2.

DETAILED DESCRIPTION

The present disclosure concerns a foam fame for the packaging ofcomputer systems, including server computer systems, and other products.Shown generally at 10 in FIG. 1 is a foam frame of a packaging system.The dimensions, features, and shape of foam frame 10 are sized andselected to accommodate a particular product. In the example of FIG. 1,the dimensions features, and shape of foam frame 10 are set toaccommodate a server computer system. Foam frame 10 includes endsupports 12, side supports 14, and slat supports 16. Foam frame 10 alsoincludes three elevated corner pieces 18. Elevated corner pieces 18include a foam corner that is elevated above the adjacent end support 14and side support 16 for better support of the unit included within thefoam frame.

Shown generally in FIG. 2 is a detailed view of corner piece 18 that isshown by the dotted lines at 2 in FIG. 1. Corner 18 of FIG. 2 includesend support 12, side support 14, and a corner support 20. Corner support20 includes a slit 22 that runs parallel to end support 12. Within slit22 is an insert 24. Insert 24 is placed within foam frame 10 at a singlelocation or multiple locations that correspond to the weakest points ofthe foam frame, including those areas of the foam frame that are mostlikely to be punctured by an external part on the unit being shipped. Asshown in FIG. 2, slit 22 and insert 24 are positioned within cornersupport 20 such that there is a significant foam thickness on both sidesof slit 22. As shown in FIG. 2, slit 22 and accompanying insert 24 arepositioned such that there is a substantial thickness of foam interiorto insert 24 (i.e., toward the center of foam frame 10) and to theexterior of foam frame 24. FIG. 3 is a cross-sectional view of cornerpiece 18 of FIG. 2 taken along the line 3-3 of FIG. 2. Shown in FIG. 3is slit 22 within corner support 20. Included within slit 22 is insert24. As shown in FIG. 3, slit 22 and insert 24 may extend through cornersupport 20 and terminate in an end support member.

In the event that the shipped unit is dropped such that the shipped unitor an external component of the shipped unit contacts insert 24, insert24 will flex and will disperse the force upon insert 24 across thesurface of insert 24 and across the foam that is behind insert 24. Theability of insert 24 to deform and spread the impact of the unit acrossinsert 24 and the foam behind insert 24 decelerates the shipped unit andprevent a hard stop of the shipped unit against a hard surface. Insert24 is sufficiently pliable that contact between the unit and insert 24does not harm the unit or the surrounding foam. Insert 24 may, forexample, be made of corrugated cardboard or a deformable plastic.

More than one slit 22 and accompanying insert 24 can be used in a singlefoam frame 10. The slit and an accompanying insert can be placed in allthose locations of the foam frame in which the foam frame will encounterextraordinary stresses or the possibility of puncture because of theshape of the unit being shipped, including the shape of any externalcomponents on the unit being shipped. As such, the use of the slit andan accompanying insert can be localized to the weakest points of thefoam frame. As compared with the option of having a reinforcing insertthroughout the entire foam frame, the use of a slit and insert in onlythose areas in which the foam frame is the most vulnerable reduces thecost and weight of the foam frame. As such, because the weight of thefoam frame is not markedly increased, the shipping weight, and thereforethe shipping cost, of the unit is not markedly increased by the presenceof one or more slits and accompanying inserts.

It should be recognized that the technique described herein may be usedwith foam frame of any size and shape, and the use of the techniquedescribed herein is not dependent on the presence of a foam frame havinga certain size or configuration. Although the present disclosure hasbeen described in detail, it should be understood that various changes,substitutions, and alterations can be made hereto without departing fromthe spirit and the scope of the invention as defined by the appendedclaims.

1. A packaging system, comprising: a foam frame sized to receive anobject; and an insert positioned within the foam frame, wherein theinsert is positioned within the foam frame such that there is asubstantial amount of foam thickness interior to and exterior to theinsert.
 2. The packaging system of claim 1, wherein the insert has asubstantially planar shape.
 3. The packaging system of claim 2, whereinat least a portion of the foam frame exists between the object and oneside of the substantially planar insert, and wherein at least a portionof the foam frame exists on a side opposite to the one side of thesubstantially planar insert.
 4. The packaging system of claim 1, whereinthe insert is positioned at a location that is prone to puncture.
 5. Thepackaging system of claim 1, wherein the insert is paper, corrugatedcardboard, plastic, or a combination thereof.
 6. The packaging system ofclaim 1, wherein the insert is positioned proximate a corner of the foamframe.
 7. The packaging system of claim 6, wherein the foam frameincludes an elevated corner piece; and wherein the insert is within theelevated corner piece.
 8. A packaging system, comprising: a foam framesized to receive an object, wherein the foam frame has a plurality ofinserts therein, and wherein at least a portion of the foam frame existsbetween the object and the insert.
 9. The packaging system of claim 8,wherein each insert is positioned at a location that is prone topuncture.
 10. The packaging system of claim 8, wherein at least one ofthe inserts is comprised of paper, corrugated cardboard, plastic, or acombination thereof.
 11. The packaging system of claim 10, wherein atleast one of the inserts is positioned proximate a corner of the foamframe.
 12. The packaging system of claim 8, wherein the foam frameincludes an elevated corner piece; and wherein at least one of theinserts and its associated corner piece are positioned within the cornerpiece.
 13. The packaging system of claim 8, wherein each insert ispositioned such that there is a substantial amount of foam thicknessinterior to and exterior to the insert.
 14. A packaging system,comprising: a foam frame sized to receive an object, the foam framehaving a first composition; and an insert positioned within the foamframe, the insert having a second composition and wherein at least aportion of the foam frame exists between the object and the insert. 15.The packaging system of claim 14, wherein the insert has a substantiallyplanar shape.
 16. The packaging system of claim 14, wherein the insertis comprised of corrugated cardboard.
 17. The packaging system of claim14, wherein the insert is proximate a corner of the foam frame.
 18. Thepackaging system of claim 8, wherein insert is at a location in the foamframe that is susceptible to puncture.
 19. The packaging system of claim8, wherein the foam frame includes an elevated corner piece; and whereinthe insert is within the corner piece.